TECHNICAL FIELD
[0001] This application is a divisional application from
EP-A- 02703025.3 and the invention herein relates to a modified single-cylinder Otto engine.
BACKGROUND
[0002] It is generally known that single-cylinder, petrol-driven Otto engines are major
environmental culprits. Lawnmowers equipped with such engines come chiefly to mind
here. Many different measures have been taken to try to reduce/eliminate the environmental
pollution above all from lawnmowers. Amongst other things, lawnmowers have been developed
that are operated electrically, either using a flex or rechargeable batteries. Battery-driven
lawnmowers have a limitation on their operating time, however, that frequently provides
insufficient capacity, and they are also still relatively expensive. Although flex-operated
lawnmowers indeed do not have these disadvantages, the flex signifies a practical
problem and also a safety risk. It can be stated that this trend in development with
regard to lawnmowers has not solved the environmental problems, since the majority
of users still want to use fuel-powered lawnmowers.
[0003] To compensate for the environmental problem of fuel-driven lawnmowers to a certain
extent, many large-scale users, e.g. local authorities, have gone over to using so-called
environmental petrol, which is very expensive (approx. 2 euro/l). It is perceived
that this extreme additional cost deters many potential users from buying this propellant.
[0004] An alternative fuel that could solve both the environmental and cost problems is
ethanol, which is a bio-fuel with combustion products that are on the whole environmentally
friendly and which is priced at roughly the level of normal petrol. However, major
manufacturers of single-cylinder Otto engines that are used in lawnmowers state that
it is not possible to modify their single-cylinder Otto engines for ethanol operation,
in spite of the fact that it has been known for over 100 years that Otto engines can
de facto be powered by means of ethanol by using a relatively high compression ratio.
Difficulties in cold starting are a general problem with ethanol as a fuel, however.
It appears that this problem has contributed to the fact that development with regard
to ethanol operation has led to increasingly sophisticated and thus expensive solutions.
A sophisticated solution of this kind is previously known for example from
US 4,522,173, in which direct injection is used and the piston in the engine is formed in a special
manner with the aim of optimizing combustion.
US 5,063,883 shows another sophisticated solution, a compensating piston mechanism being provided
in connection with the combustion space, which compensating piston mechanism provides
the possibility of varying the compression ratio, with the aim of being able to use
a fuel like ethanol. Furthermore, reference can be made to
WO 82/02576, which shows that a microprocessor is used with a similar aim. It is perceived that
such expensive solutions cannot give a satisfactory solution to the problem.
BRIEF DESCRIPTION OF THE INVENTION
[0005] It has proved somewhat surprisingly to be the case that, contrary to the perception
of current manufacturers, it is possible to convert a petrol-driven, single-cylinder
Otto engine cost-effectively to satisfactorily functioning ethanol operation, by means
of producing a modified engine according to the appending claims.
[0006] Thanks to the invention, a modified single-cylinder Otto engine is obtained with
which it is possible to use an environmentally friendly propellant. A propellant known
by the designation E85, which contains 85% ethanol and 15% petrol, is particularly
suitable.
Tests have shown that a drastic reduction in the CO emission can be obtained. Measurements
have confirmed that it is possible to obtain a CO emission as low as 0.1% in operation
under load. In addition to the environmental advantage, the cost reduction is very
large compared with using so-called environmental petrol, since the price of E85 is
approx. 1/3 that of environmental petrol. Moreover, it has proved to be the case that
the modified engine achieves higher efficiency, resulting in a further reduction in
the fuel cost.
[0007] According to further aspects of the invention, it holds good:
- that said carburettor is provided with a pump mechanism, to be able to force fuel
to said carburettor,
BRIEF DESCRIPTION OF FIGURES
[0008]
- Fig. 1
- shows a preferred modified single-cylinder Otto engine according to the invention
in cross-section,
- Fig. 2
- shows an engine according to Fig. 1 in cross-section before modification,
- Fig. 3
- shows a carburettor for the engine according to Fig. 1 in cross-section,
- Fig. 3A
- shows a nozzle forming part of a carburettor according to Fig. 3,
- Fig. 4
- shows an alternative modified single-cylinder Otto engine according to the invention
in cross-section, and
- Fig. 5
- shows a preferred air filter forming part of an engine according to Fig. 4.
DETAILED DESCRIPTION
[0009] Fig. 1 shows a single-cylinder Otto engine with an overhead valve according to the
invention in cross-section. An engine of this kind occurs extremely commonly mainly
in manual lawnmowers, the engine power normally being approx. 3 - 5.5 hp (DIN). They
are also common in so-called ride-on lawnmowers
1, but the power is somewhat greater there, approx. 8-9 hp (DIN). The engine comprises
an engine block 1 with a cylinder 2. Located on top of the engine block 1 is a cylinder
head 3. The cylinder head 3 is provided with cooling fins 3C and an opening 3E for
a spark plug. Furthermore, the cylinder head 3 is provided with through holes 3D to
screw the cylinder head 3 with its downward facing surface 3B to the cylinder head
1. In the cylinder head 3 are two valve ducts 3F, located inside which are valves
5, 5'. The valves 5, 5' are provided with a valve cone 5B that is intended to interact
with a valve seat 5C in the cylinder head 3. Each valve 5 is provided with a flat
surface 5A at its end. Situated between the cylinder head 3 and the engine block 1
is a gasket 10. A movable piston 4, which is provided at the top with an essentially
flat surface 4A, is located inside the cylinder space 2. The engine also has a cup-type
carburettor 6, with a fuel nozzle 7 and a pump mechanism 9. In addition, the engine
is provided with an air filter 8. One important aspect of an engine according to the
invention is that the play S2 between the valve end 5A and the upper surface 4A of
the piston in its upper position is extremely small, preferably approx. 0.4 - 0.6
mm. Another important aspect is that the opening 7A of the nozzle is sufficiently
great to permit an adequate fuel inflow. Finally, it is a great advantage that the
engine is equipped with a pump mechanism 9 to be able to force fuel into the carburettor
on start-up.
[0010] In connection with the modification of a single-cylinder Otto engine provided with
an overhead valve according to the invention (see Fig. 2), one starts by laying the
engine bare of necessary components such as the plastic cap and tank. The spark plug
is then removed so that the spark plug opening (3E) is exposed. Then the engine is
turned so that the valves are placed in their most extreme position, i.e. so that
both valves (5, 5') are in their most open position a set distance (A) from the cylinder
wall in the cylinder head (3). At the same time, it is ensured that the piston (4)
is located in its upper extreme position, which according to the example shown here
means that the piston top (4A) is on a level with the upper surface (1B) of the engine
block (1). In this position the distance (S1) is measured between the valve end (5A)
and the piston top (4A). This distance (S1) is also equal to the depth (B) in the
cylinder head (3) minus the distance (A) that the valve end (5A) projects from the
cylinder wall.
[0011] The minimum distance S 1 between the end 5A of the valve and the lower surface 3B
of the cylinder head is normally approx. 2-3 mm, i.e. B - A = S1, which is approx.
2-3 mm. With the aim of obtaining the optimum compression ratio to be able to use
ethanol as a propellant, a part of the material in the cylinder head 3 must now be
cut so that the play S1 between the piston top 4A and the lower end 5A of the valve
is reduced to a modified play S2 of between 0.4 - 1 mm (see Fig. 1). Thus the cylinder
head 3 is machined by means of suitable cutting machining (e.g. milling or grinding)
so that a greater part of the distance S1 is cut. More often than not, cutting of
approx. 2-3 mm is required to have a remaining gap S2 between the valve ends 5A, 5A'
and the piston top 4A. When the cylinder head 3 has been machined down and levelled,
it is held against the engine block 1 and the engine is turned round to check that
no valve end 5A, 5'A strikes against the piston top 4A. If this check turns out well,
i.e. the play lies within the preferred range, the cylinder head is fitted to the
engine block 1 with a new gasket 10.
[0012] Fig. 3 shows a detailed view of a carburettor according to the invention. The carburettor
6 is provided with a removable (via screw threads) fuel nozzle 7 in a known manner.
The carburettor 6 is also provided with a pump mechanism 9, a so-called "primer system"
9. Fig. 3A shows a detailed view of a fuel nozzle 7 for the carburettor 6. It is shown
here that the diameter d, opening 7A in the fuel nozzle has been enlarged from approx.
0.6 mm - approx. 0.7 mm, i.e. an increase in the sectional area of more than 30%,
for an engine with a power of approx. 4-5 hp. In engines of a somewhat higher power,
e.g. 8-9 hp, the diameter d is normally approx. 0.75 mm. The diameter of the existing
opening 7A is enlarged by approx. 5-20%, more preferredly approx. 10-15%, which is
applicable in principle regardless of the engine's power within the above-mentioned
ranges. To ascertain the optimum enlargement, the engine is tested in operation using
a number of different fuel nozzles that are provided with different-sized openings.
Thus when modifying the engine it is necessary to be equipped with a set consisting
of a number of fuel nozzles with openings of different sizes. When the optimum fuel
nozzle opening has thus been checked, a corresponding drill is used to enlarge the
existing opening 7A to the desired size.
[0013] Fig. 4 shows a so-called side valve engine, in an engine of this kind the valves
5, 5' are arranged in ducts 1A, 1'A in the engine block 1 adjacent to the piston 4.
The principles of modification are the same as described above. In this case, however,
the valve end 5'A does not move towards the upper surface 4A of the piston but towards
a surface 3A inside the cylinder head 3. In the same way, however, it is important
to optimize modification of the cylinder head 3 so that the remaining play S2 between
the valve top 5'A and the opposing surface 3A remains approx. 0.5 mm. In connection
with modification of a single-cylinder Otto engine provided with a supporting valve
according to the invention, one starts out however by removing the cylinder head 3.
Following removal of the cylinder head 3, the cylinder head 3 and engine block 1 are
cleaned of residues of the old gasket 10. The valves are then positioned in their
most extreme position, i.e. so that the valve 5' is in its most open position a set
distance A from the cylinder wall in the cylinder head 3. In this position, it is
measured (for example using a sliding calliper or dial test indicator) how great distance
A is. The depth B in the top is then measured. Cutting, levelling and checking then
takes place in the same way as above.
[0014] Fig. 5 shows an air filter 8 intended to be used in a carburettor 6 that is provided
with a non-removable fuel nozzle. To be able to optimize the fuel/air mixture, the
air filter 8 is provided with a choke element 8B that is provided with choke openings
8A. The choke openings are eight in number according to the practical example shown
and consist of circular holes with a diameter of 4 mm. The total opening area through
these holes is thus approx. 100 mm
2. This means a drastic reduction in the inlet area for feed air, since according to
the original design (for petrol operation) the entire intake channel is open in principle
for the flow of air, i.e. in the present case where the diameter is 34 mm an open
area of between 800-900 mm
2. The area for the fastening screw that penetrates the centre hole (8C) in the choke
element (8B) must be deducted here. It is also clear from the figure that the choke
element (8B) is cup-shaped, with outer wall parts that are converging, so that the
shape of a truncated cone is formed. This shape facilitates a simple, secure and tight
fitting of the choke element (8B). It should be made clear that this form of modification
is only a necessary alternative when the carburettor 6 is provided with a fixed non-modifiable
fuel nozzle.
[0015] In comparative tests that have been carried out, surprisingly good results have been
able to be demonstrated with the invention with regard to environmental effects. The
results of three different tests carried out are shown below. Test 1 was carried out
using Aspen environmental petrol in a new lawnmower. Tests 2 and 3 were carried out
on a used lawnmower modified according to the invention. The propellant used in tests
2 and 3 is so-called E85, containing 85% ethanol and 15% petrol.
Test 1
Type of fuel |
Emission |
Aspen environmental petrol |
|
Carbon monoxide (CO percent by vol.) |
Hydrocarbon (HC ppm) |
Carbon dioxide (CO2 percent by vol.) |
Oxygen (O2 percent by vol.) |
|
Idling speed |
0.5 |
800 |
7.0 |
10.1 |
Working speed |
No-load engine |
3.0 |
248 |
8.3 |
6.4 |
Working speed |
Engine under load |
3.4 |
138 |
8.4 |
6.2 |
|
|
|
|
|
|
Test 2
Type of fuel |
Emission |
Ethanol 85% Adjustable nozzle, adjusted to low running |
|
Carbon monoxide (CO percent by vol.) |
Hydrocarbon (HC ppm) |
Carbon dioxide (CO2 percent by vol.) |
Oxygen (O2 percent by vol.) |
|
Idling speed |
|
|
|
|
Working speed |
No-load engine |
0.1 |
787 |
6.0 |
12.2 |
Working speed |
Engine under load |
0.1 |
603 |
9.0 |
8.2 |
|
|
|
|
|
|
Test 3
Type of fuel |
Emission |
Ethanol 85% Adjustable nozzle, adjusted to steady running |
|
Carbon monoxide (CO percent by vol.) |
Hydrocarbon (HC ppm) |
Carbon dioxide (CO2 percent by vol.) |
Oxygen (O2 percent by vol.) |
|
Idling speed |
1.8 |
183 |
8.4 |
7.6 |
Working speed |
No-load engine |
2.3 |
168 |
9.0 |
5.9 |
Working speed |
Engine under load |
0.1 |
140 |
9.0 |
8.0 |
|
|
|
|
|
|
[0016] The results show that a modified engine according to the invention under load, using
E85 as a propellant, has exceptionally a much lower CO emission than test 1. The CO
emission for an engine under load was only 0.1% CO, while a lawnmower operated using
Aspen environmental petrol emitted 3.4 % CO when under load. The other values regarding
emissions are roughly comparable. The test thus shows that an engine modified according
to the invention facilitates a drastic reduction in the environmentally harmful CO
emission. We have chosen to focus on the emission levels for an engine under load,
since a lawnmower operates de facto under load during the greater period of its operation.
However, it can be noted that the CO emission is otherwise also good with regard to
an engine modified according to an embodiment of the invention.
[0017] It has also proved to be the case that an engine converted in accordance with the
invention can meet the high requirements that apply to obtain environmental labelling
according to the Swan standard, ISO 14024. In a test carried out according to test
cycle G1 in ISO 8178, by the certified testing institute MTC, the following very good
exhaust values were measured for a Briggs & Stratton Intek Edge 55 OHV (without catalyzer)
that had been modified according to an embodiment of the invention.
Briggs & Stratton Intek Edge 55 OHV (without catalyzer) |
|
CO |
HC |
CO2 |
NOX |
BF |
|
(g/kWh) |
(g/kWh) |
(g/kWh) |
(g/kWh) |
(g/kWh) |
Test 1 |
10.42 |
2.28 |
891 |
7.73 |
437.5 |
Test 2 |
10.27 |
1.98 |
906 |
7.90 |
443.9 |
Mean |
10.34 |
2.13 |
898 |
7.82 |
440.7 |
[0018] The invention is not restricted to what has been described above, but can be varied
within the scope of the following claims. Thus it is perceived inter alia that the
invention can also be applied in application areas other than lawnmowers, for example
other garden machinery and/or agricultural machinery. Furthermore, it is perceived
that the existing play S1 between critical points in the engine can be measured in
ways other than those described above, for example by means of laser meters or other
existing measuring devices. In certain extreme cases it is also conceivable for the
cylinder head to be cut by more than 100% of S1 and to use a thicker cylinder head
gasket instead as compensation.
1. Single-cylinder Otto engine for ethanol operation, which engine comprises an engine
block (1) with a cylinder (2), a cylinder head (3), a piston (4) disposed movably
inside the cylinder, two valves (5, 5') arranged by the cylinder, a carburettor (6)
with a removable fuel nozzle (7), and an air filter arrangement (8),
characterized by the combination that
a) the minimum play between the valve end (5A) and its opposing surface (3A; 4A) is
between 0.2 - 1 mm, preferably 0.3 - 8 mm, more preferredly 0.4 - 0.6 mm, and,
b) the fuel nozzle (7) is provided with an opening (6A), the diameter of which is
between 5-20%, more preferredly 10-15%, greater than the corresponding opening (6A)
for petrol operation.
2. Single-cylinder Otto engine according to claim 1, characterized in that the carburettor (6) is provided with a pump mechanism (9).
3. Single-cylinder Otto engine according to claim 1 or 2, characterized in that said engine is an overhead valve engine, said minimum play (S2) being present between
one valve end (5A) and the upper surface (4A) of the piston in its upper position.
4. Single-cylinder Otto engine according to claim 1 or 2, characterized in that said engine is a side valve engine, said minimum play (S2) being present between
a valve upper end (5A) and a surface (3A) inside the cylinder head (3).
5. Single-cylinder Otto engine for ethanol operation, which engine comprises an engine
block (1) with a cylinder (2), a cylinder head (3), a piston (4) disposed movably
inside the cylinder, two valves (5, 5') arranged by the cylinder, a carburettor (6)
with a non-removable fuel nozzle (7) and an air filter arrangement (8),
characterized by the combination that
a) the minimum play between the valve end (5A) and its opposing surface (3A; 4A) is
between 0.2 - 1 mm, preferably 0.3 - 8 mm, more preferredly 0.4 - 0.6 mm, and,
b) the air filter (8) in the intake channel is provided with a choke element (8B)
containing a restriction (8A) that reduces the total opening area to 50 - 200 mm2, preferably 80 - 150 mm2, more preferredly 90 -120 mm2.
6. Single-cylinder Otto engine according to claim 5, characterized in that the carburettor (6) is provided with a pump mechanism (9).
7. Single-cylinder Otto engine according to claim 5 or 6, characterized in that said choke element (8B) is cup-shaped, preferably having a centrally arranged hole
(8C) for fastening.
8. Single-cylinder Otto engine according to claim 7, characterized in that said choke element (8B) is arranged with converging outer walls.
9. Single-cylinder Otto engine according to any of the above claims, characterized in that said engine is disposed on a lawnmower.